Fabric manufacture



0d 291 1935'- H. l., sHUTTLEWoRTH ET A1. 2,018,927

FABRI C MANUFACTURE Filed Dec. 2l, 1933 ATTORNEY Patented Oct. 29, 1935 UNITED STATES PATENT OFFICE FABRIC MAN UFACTURE Application December 21, 1933, Serial No. 703,362

17 Claims.

This invention relates to pile fabrics, such as are used for rugs or the like and have a pattern on the pile. More particularly, the invention is concerned With the manufacture of such pile fabrics in which the pile pattern is produced by the use of pile yarns which are colored by being printed While they are Wound on a drum, preliminary to the weaving operation. The invention includes not only a novel fabric of the type referred to but also a method of producing this fabric in accordance with which a single drum printing apparatus may be used for the preparation of the yarn for the Weaving of fabrics having a large variety of patterns and varying heights of pile. i

In the manufacture of pile fabrics in which the pattern on the pile is produced by the use of pile yarn strands which are colored at intervals along their length in accordance with the pattern to be produced, one method of preparation of the pile yarn involves winding each individual strand on a drum, applying the colors to the yarn so as to form stripes on the cylindrical yarn mass, and then removing the yarn from the drum and treating it to set the color. When all of the strands to be used in a fabric havev thus been printed, the strands are Wound on a loom beam, the individual strands first being set by hand so that the areas of color on the strands assume their proper relative positions. When the yarn thus set and Wound onthe beam is used in the Weaving of the fabric, the colored portions of the yarn appear as pile tufts in the fabric in their proper relative positionsdetermined by the pattern to be produced. According to this method of preparing the yarn, each single strand is colored at appropriate intervals along its length according to the desired pattern which is repeated along the entire length of the strand, and the length of a strand printed in one operation is sufficient for the Weaving of a substantial length of fabric.

In the Weaving of pile fabrics in which the pile is formed of pile Warp yarns raised out of the fabric by being looped over pile Wires by heddles, several inches of each strand of pile Warp are required in the Weaving of one inch of the completed fabric, and the length in inches of a single strand of pile yarn required for the Weaving of an inch of completed fabric is known as the yarn ratio. This ratio depends on the height of the pile, and the ratio of fabric take-up to the number of picks inserted. In a typical fabric of the kind referred to, the yarn ratio may be as much as seven, this ratio signifying that seven inches of each yarn strand appear in each inch of the completed fabric.

In the present practice of Weaving fabrics in Which the pile is made up of pile Warp yarn printed on a drum, a single supply of warp yarn 5 is used for the pile. If the fabric is of indefinite length, as for example, carpet fabric, the pattern on the face of the fabric is repeated an indenite number of times on the fabric, and the locations of the boundaries of the repeats of the pattern relative to the length of the fabric are unimportant. Accordingly, the yarn for the pile is Wound on the drum up to the capacity of the drum, and it is only necessary to use a pattern which has a repeat on the yarn, which is a factor of the drum circumference. For example, the yarn pattern repeat may equal the drum circumference, in which event, the length of a repeat on thel face of the finished fabric is equal to the circumference of the drum divided by the yarn ratio. Instead of using a pattern having a yarn repeat equal to the circumference of the drum, the yarn pattern repeat may have a length equal to onehalf', one-third, or some smaller fraction of the drum circumference. When the yarn pattern 25 repeat is shorter than the drum circumference, the application of the colors to the yarn on the drum is repeated a number of times during the printing operation until the entire mass of yarn on the drum is fully printed.

When drum printing is used in the preparation of yarn to be woven into rugs in accordance with present practice, new problems are presented, particularly when the rugs have a face pattern consisting of a border enclosing a central design, and because of these problems, which have not heretofore been solved, the use of drum printing in connection with the production of such rugs has been greatly restricted.

In such a rug, the entire face is covered by a single repeat of the pattern, and the length of the yarn required for such a lrug is, therefore, equal to the length of the rug multiplied by the yarn ratio. This product is the length of a yarn pattern repeat, and if the yarn is to be: printed 45 on a drum, the circumference of the drum must be equal at least to the 'length of the yarn pattern repeat, although the circumference may be equal to the length of the yarn pattern repeat multiplied by a Whole number. Accordingly, if 50 this method Were to be used in the production of a rug of substantial size, such as 9 x 12', With a yarn ratio of 7, the length of the yarn pattern repeat Would be 12 X 12', or 144, multiplied by '7, or 1008. Accordingly, it would be necessary Y to use a drum having a circumference equal to 1008" in the printing of such yarn. A drum of that circumference would have a diameter of approximately 27' and such a. drum is much too large for commercial purposes since its construction would present difficult problems and great difficulty would be encountered in the removal of theyarn from the drum after the printing operation and in the handling of such a length of yarn in the subsequent Voperations of setting the color and washing the yarn to remove excess coloring matter. A

The usual drums now employed in manufacturing plants equipped for Ythe production of fabrics of the type describedhave a diameter of l2 or under and bythe use of such drums, itis possible to apply to the yarn a pattern having a yarnV repeat of approximately 450". This' yarn when employed at a'pile yarn ratio of 7 canbe used to produce a rug approximately 64" long and rugs of that length are of limited commercial value. If the yarn printed on such a drum were used on Aa 9 x 12 rug having a border, the maximum yarn ratio that could be used would be slightly more than 3. -Such a ratio corresponds to a low pile which does not give proper coverage of the web of the fabric and a fabric so wovenV is `not satisfactory.

In some rugs, in which the face pattern does Vnot include a central design enclosed in al border,

yarn ratio of '7, requires 1008" of yarn but the yarn pattern repeat 'is only504 long. r'l'he drum required for printing such yarn would have a diameter of approximately 121/2 and such a drum could be built and used. But in the production of rugs by present methods, a single drum rcan be used `for printing the yarn for rugs of only a small number of sizes woven with a givenV pile `yarn ratio, and the yarn printed on commercial drums can be woven only into relatively small rugs having a pattern which comprises an enclosed central design.

' From the foregoing, it will be apparent that the use of the method of rug production involving the use of drum printing above described has necessarily been greatly restricted and mills equipped withdrum printing apparatus have lost much business because of their inability to produce rugs in all sizes and with the high pile pro- Y vided in rugs woven in accordance with other Y i methods. Y

to the provision of a novel rug having a pattern The present 'invention is accordingly directed on the pile produced by the use of drum printed pile yarn and the new fabric can be woven without difficulty in the Usual patterns consisting of van exterior or border portion and an interior dea .plain border or aborder which embodies a de- K sign. `The method' of fabric production of the invention maybe used in the manufacture of theY new fabric woven of yarn producedwithout difficulty on drums of ordinary size, and it affords special advantages in the Vproduction of rugs as a continuous succession.

f The new fabric differs from prior fabrics woven Yby the use of drum printed Warp in. that the pile is woven from two separate supplies and the yarns from both supplies are present together throughout the fabric. The pile of the rug is then subdivided and the pile in one subdivision is produced of yarn from onefsupply and the pile in the other sub-division is produced of yarn from the other supply.

YThe pile surface may be sub-divided in various ways, as, for example, in a rug Yhaving a border surrounding .a center design, the pile surface may be made up of two'sub-divisions, one consisting of both end borders and the other consisting of the two side borders and the central design.

When thepile surface is thus sub-divided, printed includes the central design, while in the other sub-division, which includes the two end borders the yarnused may be either dyed or printed, rthe latter beingrused when there is a design contained in the end border, such, for example, as one corresponding to a design in the side borders. Instead of that method of sub-dividing the pile surface, the surface may be sub-divided trans' versely, in which case, in a rug having a border, each sub-division Vconsists of an end border, half the length of each side border, and half the interior design. Since each of such sub-divisions includes apart of the interior design, the production of such a rug requires the use of printed yarn for both supplies. Regardless of the method of sub-dividing used, the pile surface in each subdivision is made from yarn of a single supply, and in'that sub-division, the yarn from the other supply lies in the body of the fabric as dead yarn.

The new fabric may advantageously take the form of a continuous succession of rugs, each of' which has a'pattern consisting, for example, of a' border surrounding an interior design with successive rugs separated by a narrowed heading. In each such rug, yarns from two supplies are used for the pile, and the lengthof yarn from each supply which is employed in the rug is suflicient to provide the yarn which appears as pile inV one` sub-division of the rug-and also to provide the yarn which underlies the pile surface in the other sub-division as dead yarn, and the dead yarn which forms part of theheading's.

The printed yarn employed in such a rug has printed upon it a pattern selected so that, in the length of'yarn required for therug, there is either a single yarn pattern repeat or a multiple of such repeats, and the printed yarn used in the rug maybe printed throughout its entire length, even though only a portion of the yarn is to be exposed in the rug as pile while the remainder of the yarnis dead, or the printing may be confined to such portions of the yarn as are to be exposed iasV pile.

ByV employing yarn from two different supplies for the pile, with the yarn from both supplies present throughout the rug .and with the .yarn from one supply providing the entire pile in a sub-division of the rug, in which sub-division the yarn from the other supply is present as dead yarn, and vice-versa, and by using a pattern which gives a yarn pattern repeat of the length mentioned, it is possible to produce the new fabric in a variety of patterns having pile of allY practi calheights and to manufacture the fabric lin the form of rugs of all commercial sizes.

'I'he new method of fabric production of the invention involves the correlation of a-number of factors which include the layout of a single unit length of the fabric, the circumference ofthe drum to be used in printing the yarn for the fabric, and the length of the pattern to be applied to the yarn. Also, in the case of a rug which has borders and a central design, the relative lengths of the borders and central design are additional' factors to be correlated. In selecting the layout mentioned, it is necessary to take into account both the total length of the unit. of the fabric, which in the case of a rug includes both the pile surface area and the headings, and also the pile yarn ratio. In some instances, the length of each supply of printed yarn in a unit of the fabric may be equal to the circumference of the drum on which the printing is to be done, but more frequently the length of the yarn in one or both supplies is a multiple of the circumference of the drum, or a multiple of the circumference plus an overlap. Since the drum is to carry the yarn for a large number of rugs and the pattern is to be applied to the entire yarn mass on the drum in accordance with the method of the invention, the pattern to be adopted is one which has a yarn pattern repeat which is a factor of the drum circumference and also a factor of the overlap. Also, in order that the face pattern of the pile may be attractive, the length of the yarn pattern repeat must exceed the pile yarn ratio.

When these conditions are observed, it is possible to print the yarn for each supply to be used for a continuous succession of unit lengths of the fabric without employing a drum of excessive size. But since the drum circumference is fixed and the unit length, as for example, the length of a rug, is fixed, it may be necessary in accordance with the principles of the invention to depart from the preliminary layout of the unit in order that the length of the yarn in each supply may be printed on the drum with a desirable pattern. In making such changes, minor variations in the pile yarn ratio may also be made in order to meet the required conditions.

Ordinarily in putting the principles of the invention into practice, the user will select a drum of a given diameter and' then make a preliminary layout of a unit length of the fabric. This layout will show the sub-divisions of the fabric in which the yarn from the different supplies provides the pile. Knowing the length of these sub-divisions on the layout and the pile yarn ratio, the designer can then determine the length ofV the yarn in each supply required in the fabric unit. He can also determine the length of the yarn pattern repeat that can be used in the printing of the two yarnsupplies on the drum, and if the pattern is of an acceptable length, the layout may be adopted. However, since the pattern employed on each supply must 'have a yarn pattern repeat, the length of which is a factorl of the length of that supply in a unit length of fabric, .a factor of the drum circumference, and a factor of the overlap, in case the length of the yarn in the supply for a unit length fabric is equal to a multiple of the drum circumference plus an overlap, it sometimes happens that in the case of one supply, for example, the only pattern which meets the conditions has a very small yarn pattern re.- peat. When this occurs, changes in the relative lengths of the supplies of yarn needed for the fabric are necessary. These lengths may be varied in different ways, as for example, by changing the pile yarn ratio, or by altering the lengths of the sub-divisions as measured along the fabric. In the case of a rug having end borders and a central design with one sub-division including both end borders and the other consisting of the central design, the relative lengths of the yarn in the two supplies .used for producing the rug may be varied by changing the layout to increase the total lengths of the end borders and decrease the length of the central design, or vice-versa. By taking advantage of the several variations, the designer can readily adopt a layout and pile yarn 5 ratio which permit the printing of theV pile yarn on the available drum.

In a case. of some rugs having end borders with a face pattern and a central design, it may not be possible. to produce a fabric of the desired appearance, when a single drum is used for printing the supplies of yarns used both for the end borders and for the central design. In that situation, the problem can ordinarily be solved by the employment of commercial drums of two different sizes for the printing of the two different supplies. 4When two different drums are used, the correlation of the factors previously mentioned is carried on as before and such variations are made in the preliminary layout and the pile yarn ratio as may be required.

The weaving of fabrics to be produced in accordance with the new method can be carried out on a loom ofthe standard construction employing single print beams with certain minor modications. This loom is provided with separate beams for the two different pile warp supplies and separate heddles are provided for controlling the pile warps from the two beams. The heddle mechanism is so constructed that while the warp from one beam is being used for forming tufts, the yarns from this beam are raised at appropriate intervals so that the pile wires may be properly inserted. During this period of loom operation, the yarn from the other beam is manipulated by its heddlesl so that it lies in the plane' of the stuffer warps as dead yarn. Except for these changes, the loom is similar to standard looms now in use and it operates to weave fabric in the same way.

As pointed out above, the principles of the invention may be applied to production of a fabric in which two supplies of pile warp yarns are used and the yarns in one or both of these supplies may be printed, dependent upon the manner in which the pile surface of the fabric is sub-divided and also upon the character of the end borders. For purposes of explanation, the application of the principles of the invention will be described in connection with the production of a fabric made in the form of a continuous succession of rugs by the use of two supplies of printed yarn, the pile surface of the rug being sub-divided so that one sub-division includes the end borders only and the other includes the central design and the side borders. It is to be understood, however, that the utility of the invention is not limited to a fabric of these specific characteristics.

For a better understanding of the invention, reference may be had to the accompanying drawing, in which Figure l is a plan view of a portion of the fabric woven as a continuous succession of rugs;

Figure 2 is a longitudinal sectional View on an enlarged scale through the fabric Woven as shown in Figure l and illustrating the method of weaving; and

Figure 3 is a transverse section on the line 3--3 70 of Figure 2.

Referring now to the drawing, there is illustrated in Figure l a length of thev new fabric woven as a continuous succession of rugs, and one such rug I0 has a pile surface with a pattern 75 -shots in place.

made upof end borders II and I2, side borders I3,*and an interior design I4. Successive. rugs are separated by headings I5 whichrhave no pile thereon, and after the completion of the weaving,`

the individual rugs are separated by severingfthe headings ,along the dotted lines I6.

The fabric shown in Figure 1 may be of the various standard weaves, as, for example, there' may be two or three shots of weft per row of tuftsl and one or two sets of binder warps. The pile f yarn may be employedV to provide a pattern on the face only, or on both face and back, and the pile may be cut or uncut. The fabric illustrated in Figure 2 is of the two-shot variety with the vpattern of the pile also appearing on the back This fabric comprises stuffer warps I l, Weftshots I8 inserted above and below the stuer warps, and two sets of'binder warps I9 holding the weft in the fabric are from two different supplies, the

,yarn 29 from one supply being employed as pile vonly in the end borders II and I2, and the yarn l 2! from the other supply being used as pile in the Vside borders and the interior design.

As shown in Figure 2, pile yarns from each supply are present together throughout the entire fabric, but in thoseY portions of the fabric in which the yarn from one supply is being used asV pile, the yarn from the other supply lies within the fabric as dead yarn. Thus, in the weaving of the` end borders, such as I I, the pile'yarn 2 is raised out of the fabric at appropriate intervals bythe wiresV 22 to form tuft loops, and in this portionof the fabric, the yarn 2I lies in the body of `the fabric as dead yarn. In that portion of the fabric Abetween the end borders, the yarn 2l is raised out of the fabric at the proper intervals by the pile Wires to form pile loops, while the yarn 20 lies in the body of the fabric as dead yarn. On the headings, there is no pile surfaceV and consequently in these portions of the fabric, the

pile yarns 2D and 2I from both supplies are deadV yarns within the body of the fabric.

In the preparation of the yarnfor the weaving Y printed preliminary to the weaving operation.

In the printing ofthe yarns for the production of a continuous succession of rugs, a number of different situations may arise. Assuming that the yarn from one supply only is printed, then in order that the printed yarn for a succession 0f rugs may be printed on the drum, it is necessary to selecta pattern, the length of a face pattern repeat of which bears a definite relation to the Vlength of the yarn employed in a single rug and extending from the line on which onejheading isV 1 cut to the line of severance of the next heading; Ythat is, in the fabric illustrated in Figure 1, the

length of the. yarn from the printed supply used in a single rug extends from one line I6 to the next line. I6 and the length of the yarn thus depends not only on the overall length of the rug but on the proportion of that length in which the,V

For example, that length yarn appears as pile. Y ofthe yrug between the dotted lines 23-23 deiining the boundaries of the interior design, may

be 120 inches, and if the yarn ratio is seven, 840 inches of yarn are required in that portion of the rug for use as the pile. In the end borders The pile Warp yarns employed circumference and of the overlap.

Vsmaller than a suitable pile yarn ratio.

and the headings, the yarn appearing as pile in the central design is dead yarn, and in that case. the yarn ratioy may be two or under. ly, in selecting Va pattern, the total length of yarn from the printed supply must be considered and the pattern must have a yarn pattern repeat,

According- Y the length of which is equal to oran' arithmetical Y* factoriof the total length of the yarn required. Invprinting the yarn for a supply on the drum, the method of applying the colors requires that the length ofY a yarn pattern repeat be an arithmetical factor of the drum circumference. If the length of the repeat is equal to the drum circumference, the colors are applied to the yarn on the drum in accordance with the requirements of a. single pattern but if the length ofl the regle application of coloris duplicatedon each half of the drum.

In the production of rugs `by .the new method, itfrequently-ihappens that the length Aof a supply ofyarn required in a rug is equal to the number of complete Wraps around the drum, plus a. fractional part of the drum, as for example, the length 'of the yarnrrequired may.' equal two complete wraps around the drum plus an overlap of a given number of inches. When that situation arises, the pattern selected must have a yarn pattern repeat which is a factor both of the drinn The colors are then applied to the yarn on the drum with the pattern repeated until the entire yarn mass is colored. When this procedure is followed, the yarn for a large number of rugs .to be woven in succession may be printed in one printing operation with the colors applied in stripes which extend parallel to the axis of the drum.

In order that the correlation of the factors previously mentioned may be understood,V a specinc example will be given. Assuming that the rug requires printing of Yonly one supply of. yarn,

- that the preliminary layout of the rug involves the use of yarn in theprinted supply having a length of 915 inches, and that this yarn is to be printed,Y on a standard drum of 225" circumference, it will-be seen that the length of this yarn used'in a single rug will make fourcornplete wraps around thedrum and will cover an addi-V tional fractional part'of the drum equal to 15". The common factors of the drum circumferenceand of the fractional part are 3, 5, and 15,

and the pattern selected may have a yarn repeat of a Vlength in inches equal to any one of these factors, since a pattern having a yarn repeat of one of these lengths may be applied to the yarn Vmass on the 225V drum in such manner that the mass carries a wholefnumber of the yarn repeats.

However, of the factors mentioned, onlyY 15 exceeds the pile yarn ratios ordinarily used and if the'yarn pattern repeat is of vless length than the ratio, the face pattern repeat will be less than an inch long. vThis is usuallyV objectionable and, therefore, in the specific example'given, the

pattern employed will have a yarnrepeat of 15".

From the specific example, it will be apparent Vthat a situation may arise in which theV yarn employed in one supply in the rug exceeds a whole number lof wraps about the drum by an overlap, which has no common factors with the drum circumference, or in which the common factors of the overlap and circumference are When that situation arises, a variation in the layout of the rug is adopted so that the length of the supply may be changed to a value such that the common factors of the overlap and the drum circumference represent a yarn pattern repeat of a desirable length.

As a specific example of the method of correlating the various factors involved in the production of rugs, the following is given:

In the fabric illustrated in Figure l, the interior design Id includes three columns of blocks of color extending lengthwise of the fabric, and in any one of these columns, the blocks 25, 26, and 27 are all of the same size, and each one may include, for instance, four tufts arranged lengthwise of the fabric. The end blocks 28 and 29 in a column are of less length and each oneis shown as including three tufts in a lengthwise row.

The yarn which is used for the pile in the interior design must have a length equal to the length of the design multiplied by the pile. yarn ratio, plus a length equal to the sum of the lengths of the end borders and of the headings multiplied by the dead yarn ratio. The yarn used for the pile in the end borders must have a length equal to the sum of the lengths of the end borders multiplied by the pile yarn ratio, plus the sum of the lengths of the interior design and of the headings multiplied by the dead yarn ratio. In producing the rug, the total length ofthe rug between the headings will be selected in advance and will ordinarily be the lengthwise dimension of a rug of standard commercial size. Also, the circumference of the drum on which it is desired tov print the yarn is known.

As a matter of convenience in computation, it may be assumed that the length of the yarn used in the end borders of the rug is equal to the drum circumference, since if that relation prevails, the pattern can be applied to that yarn in such manner that only those portions of the yarn need be printed which are to be exposed in the rug. However, the length of the yarn may be assumed to be either a factor of the drum circumference, or a multiple of the drum circumference, or the drum circumference or a multiple thereof, plus a fractional part. If the yarn length is assumed to be half the drum circumference, the printing opera.- tion is simple and only such parts of the yarn need be printed as are to be exposed as pile, whereas if the length .is greater than the drum vcircumference, then the yarn has to be printed throughout its length.

In printing the yarn which is to appear as pile in the center design, the length of the yarn printed must be such that if it were all used as pile at the pile yarn ratio, it would provide a pile surface equal in length to the length of the center design, plus an additional amount of pile surface at either end thereof. The length of the yarn in these additional surfaces would then be equal to the sum of the length of the end borders and the length of the headings multiplied by the dead yarn ratio. The additional surfaces beyond the central design which can be provided with a pile surface by the yarn employed as pile in the central design are indicated in Figure 1 as lying between the dotted lines 23 and 24 at each end of the design, and with the pattern illustrated in which the interior blocks 25, 26, and 21 are each four tufts long, these additional surfaces are sufficient to bring the end blocks 28 and 29 up to the size of the interior blocks.

In the drawing, each end block contains three tufts in a lengthwise row and the entire amount of the central design .pile yarn in the `rug is such that if it were all employed as pile, it would provide each end block with an additionaltuft and thus make the end blocks and interior blocks all of the same size. That part of the yarn which is not used in the end blocks and which would add an additional tuft thereto is sufcient in length to be employed as dead yarn at the proper `dead yarn ratio in those parts of the rug lying between the ends of the central design land the line of severance of the headings; that is, between the lines 23 and l5 at each end of the rug.

The statements given of the essential conditions as to the lengths o-f the yarns lto be used in the rug provide a basis for the formulation of equations by which the variables may be determined. In employing such equations, the drum diameter is assumed and the length of the yarn to be used in the end borders is likewise assumed as equal to the drum circumference. Suitable yarn ratios throughout the rug are then adopted, whereupon the length of the central design, the end borders, the headings, and the additional surfaces lying between the lines 23 and 2 may be calculated. With these values known, the length of the yarn to be used-)as pile in the central design can be determined. Thereafter a pattern can be selected which has a repeat of suitable length.

In employing such'equations with a given drum diameter, it may develop that the pattern which it is possible to use has a yarn repeat too short for commercial purposes. In that situation, a drum of a different size may be used or the length of the central design of the rug may be varied, after which the calculations to determine the length of the end borders and headings are repeated. By altering the variable factors, the lengths of the central design, of the end borders, and of the headings may be so correlated that the lengths of the yarns from the two supplies which `are to be used in the rug can be printed on an available drum with a yarn pattern repeat of a size which permits the printing of the supplies of yarn. on that drum.

What we claim:

1. A rug which comprises stuifer warps, weft shots inserted above and below the stuffer warps, binder warps crossing over and under the weft shots to bind them in the fabric, and pile Warp yarns in two different groups presen-t together throughout the fabric with all the yarns of one group forming the entire pile in one sub-division of the fabric and all the yarns of the other group forming the entire pile in another sub-division of the fabric, the yarns of each group lying as dead yarn in those sub-divisions of the fabric in which the yarns of the other group form the pile, each said sub-division including a multiplicity of rows of pile tufts, the pile Warp yarns in one group having colors thereon in accordance with a pattern, said pattern having a yarn pattern repeat, the length -of which is a factor of the length of said yarn present in said rug.

2. A rugl which comprises stuffer warps, weft shots inserted above and below the stuffer warps, binder warps crossing over and under the weft shots to bind them in the fabric, and pile warp yarns in two different groups presenttogether throughout the entire fabric with all the yarns of one group forming the entirev pile in vonesubdivision of the fabric and all the yarns of the other group forming the entire pile in another sub-division of the fabric, the yarns of each group lying as dead yarn in those sub-divisions in which the ,yarns of the other group form the ityof rows of pile tufts, the pile warp yarns in together throughout the entire fabric with all' the yarns of one vgroup forming the entirepile in one sub-division of each unit length of the fabric and all the yarns of the other group forming the entire pile in another sub-division of each unit length of the fabric, each said subdivision including a multiplicity of rows of pile tufts, the pile warp yarns of each supply lying as dead yarn in ,those` sub-divisions in which the yarns of theother group form the pile, and the yarns in both groups lying as dead yarn in the headings, the yarns in' at least one group ,having colors thereonY in accordance with the pattern, the length of a yarn pattern repeat of Ywhich is a Vfactor of the length Vof the yarn present in a4 unit length of fabric plus two half` weaving a rug with said yarn and yarn from another supply as pile warp yarn raised out of the fabric in different sub-divisions thereof to produce apile, the yarns from both supplies being present together throughout the entire fabric andthe yarn from' each supply lying as dead yarn in those sub-divisions of the fabric in which v the yarn from the other supply provides the pile.

v5. A method of producing pile surfaced rugs rwhich comprises winding pile warp yarn on the surface of a drum, applying ,stripesV of color in accordancefwith a pattern to said yarn mass, said stripesYV running parallel to theaxis of the drum and saidlpattern having a yarn pattern repeat, the length of which is a factor of the length of said yarn used in Vone of said rugs, and

f' a factor of YYthe circumference of the drum Von drum and said pattern having a yarn pattern repeat, the length of which is a factor of the lengthlof said yarn used inone of said rugs, and a factor of the circumference of the drum on which it is printed, said length of repeat, when said length of yarn. is equal to a whole number' of .wrapsrabout the drumrplus a fractional part thereof, being also a factor of said fractionalV part, and weavingv a rug with said yarn and yarn from another supply as pile Warp yarn raisedvout of the fabricin. different sub-'- divisions thereof to produce a pile, the yarns from both supplies being present together throughout the .entire fabric. Y

'7. A method of producing pile surfaced rugs vwhich comprises Winding a supply-of pile warp 5 yarn on the surface of a drum, applying stripes.

' ofcolor to said yarn mass in accordance with a pattern, said stripes running parallel to the axis l of the drum, drum-printing another supply of pile warpyarn, the patterns applied to said supplieseachyhaving aV yarn pattern repeat, they length of which is a factor of the length of the yarn to which it is applied which is present in f a rug, and Weaving said supplies of pile warp yarn into a fabric with the yarns from both supplies present together throughout the fabric and said yarns raised out of the fabric in different sub-divisions thereof to produce a pile, the yarnV from each supply being present in the fabric as dead yarn in each sub-division of the fabric in 20 which theyarn from the' other supply provides the pile.

8. A method of producing pile surfaced rugs which comprises winding a' supply of pile warp yarn on the surface of a drum, applying stripes 25 of color to said yarn mass in accordance with a pattern, said stripes running parallelr to the axis of the drum, drum-printing another supplyY of pile warp yarn, the patterns applied to said supplies each having a yarn pattern'repeat, the 30 length of which is a factor of the length of the yarn to which it is applied which isv present in a rug, andalso a factor of the circumference of the drum on which it is printed, and weaving said supplies of pile warp yarn into a fabric with 35 the yarns from both supplies present together throughout theV fabric and said yarns raised out of the fabric in different subdivisions thereof to produce a pile. Y Y

9. A method of producing pile surfaced rugsy which comprises winding a supply of kpile Warp yarn on thesurface of a drum, applying stripes of color toy said yarn mass in accordance withca pattern, said stripes running parallel to the axis of the drum, drum-printing another supply of pile Warp yarn, the patternsapplied to said supplies each having a yarn pattern repeat, the length of which is a factor of the length of the yarn to which it is applied which is present in a rug, and also a factor of the circumference of 50 v the drum on which it is printed, and which, when said length of the yarn is equal to a whole number, of wraps around the kdrum plus a fractional part thereof, is a factor of said fractional part and weaving said supplies of pile warp yarn into a fabric with the yarns from both supplies present Ytogether throughout the fabric and said yarns raised out of the fabric in differentrsub- Y divisions thereof to produce a pile. Y

10. A method of producing pile surfaced rugs,'60 each having a pile surface made up of end borders,.side borders, and a central design and having headings at the ends of the end borders, whichv comprises drum printingY patternsV on two supplies of warp yarns, one of said supplies to be employed for the pile in the end borders and the other to be employed for the pile in the side borders and central design, the pattern to be apV plied on eachyarn having a yarn pattern repeat, the length of which is a factor of the length 70 A of the total amount of said yarn presentin a rug and a factor of the circumference ofthe drum on which said yarn is printed, correlating the'v relative lengths of the yarns from the two supplies present in the rug by adjustment of the length of the central design relative to the sum of the lengths of the end borders and headings to permit the use of a repeat of a desired length, and weaving the pile yarns into a fabric in which yarn from each supply is present throughout.

11. A rug having a pile surface which comprises stuifer warps, weft shots lying above and below the stuffer warps, binder warps crossing the weft shots and holding them in place, and pile warp yarns drawn from two different supplies, the yarn from both supplies being present throughout the rug and the yarn from said supplies being raised out of the fabric in different sub-divisions of the pile surface to produce pile, the yarn from at least one supply carrying a pattern printed thereon and the yarn from each supply being present in the fabric as dead yarn in each sub-division in which the yarn from the other supply forms the pile.

12. A rug provided with a pile surface having end borders, side borders, and a central design within said borders and headings beyond said end borders, which comprises stuiler warps, weft shots lying above and below the stuifer warps, binder warps crossing the weft shots and holding them in place, and pile Warp yarns drawn from two different supplies with yarn from both supplies present together throughout the entire rug, theyarn from one supply being raised out of the fabric to provide the entire pile in the side borders and central design and lying as dead yarn within the end borders and headings, the yarn from the other supply being raised out of the fabric to provide the entire pile in the end borders and lying as dead yarn within the side borders and central design and the headings, the

l yarn providing the pile in the central design having a pattern printed thereon and the total length of said yarn in the entire rug being sufficient to provide the entire pile in a surface equal in length to the length of the central design plus an additional length, the amount of yarn available for said additional length being just suicient to provide the dead yarn present in the end borders and headings.

13. A rug provided with a pile surface having a design and headings at the ends of the pile surface, which comprises stuifer warps, weft shots lying above and below the stuifer warps, binder warps crossing the weft shots and holding them in place, and pile warp yarns from two different supplies with yarns from both supplies present throughout the fabric, the pile yarns both carrying a pattern printed thereon and the yarn from each supply being raised out of the fabric to provide the entire pile on one portion of the design and lying as dead yarn beneath the remainder of the pile surface and in the headings, the total length of the yarn from each supply present in the rug being sumcient to provide the entire pile in a surface of the length of said por-` tion of the pile surface of the rug in which said yarn appears as pile, plus an additional length, the amount of yarn available for said additional length being just suicient to provide the dead yarn present beneath the remainder of the pile surface and in said headings.

14. A rug which comprises stuifer warps, weft shots inserted above and below the stuffer warps, binder warps crossing over and under the weft shots to bind them in the fabric, and pile warp yarns from two different supplies present together throughout the fabric and raised out of the fabric to form pile in different sub-divisions of the fabric, the pile yarn from each supply lying as dead yarn in those sub-divisions of the fabric in which the yarn from the other supply forms the pile, the pile warp yarns from each supply having colors printed thereon in accordance with a pattern, the pattern on each yarn having a repeat, the length of which is a factor of the lengths of both yarns present in said rug.

15. A rug which comprises stuffer warps, weft shots inserted above and below the stuffer warps, binder warps crossing over and under the weft shots to bind them in the fabric, and pile warp yarns in two different gro-ups present together throughout the entire fabric, the yarns of each group having colors thereon with the colors applied to the yarns by printing in accordance with the pattern and the yarns in each group providing the entire pile in half of the rug dened by a transverse line, all the yarns in each group being present as dead yarns in that sub-division of the rug in which the other yarns provide the pile, the colors printed on said yarns being so correlated with the positions of said yarns in the fabric that the pile produced by said yarns throughout the entire rug carries a predetermined design.

i6. A method of producing pile surfaced rugs which comprises winding a supply of pile Warp yarn on the surface of a drum, applying stripes of color to said yarn mass in accordance with a pattern, said stripes running parallel to the axis of the drum, thereafter winding a second supply of pile warp yarn on said drum and applying similar stripes of color thereto in accordance with another pattern, the patterns applied to said supplies each having a yarn pattern repeat, the length of which is a factor of the length of the yarn to which it is applied which is present in 4said rug, and also a factor of the circumference of said drum, and weaving saidsupplies of pile warp yarn into a fabric with yarns from both supplies present together throughout the fabric and with each yarn raised out of the fabric to produce the entire pile in a sub-division thereof, the yarn from the other supply lying as dead yarn in said sub-division.

17. A method of producing a continuous succession of rugs having a pile surface with individual rugs separated b'y headings lacking pile, which comprises drum printing a supply of pille yarn in accordance with a pattern having a yarm pattern repeat which is a factor of the circumference of the drum used in the printing and is also a factor of the length of said yarn which is to be present in a single rug plus two half headings, and weaving a fabric with said printed yarn and yarn from another supply as pile Warp yarn with the yarns from both supplies present throughout the entire fabric, and each yarn raised out of the fabric to form the entire pile in a sub-division of a unit of the fabric lying between a pair of headings, yarns from both supplies being present in the headings as dead yarn and the yarn from each supply being present as dead yarn in the sub-divisions in which the yarn from the other supply forms the pile.

HOWARD L. SHUTTLEWORTH. GARFIELD J. UNDERWOOD. WILLIAM H. HOWE. 

